D13802 Withcorrections
D13802 Withcorrections
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Article in Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering · May 2004
DOI: 10.1243/095440704774061156
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Abstract: This paper describes two experimental facilities and a piece of software designed to serve
as a teaching aid for automotive engineering. The first experimental rig is an antilock brake system
(ABS) workbench for a scaled-down heavy-vehicle tri-axle configuration. The second facility is a
tyre-testing sliding table used to show the forces and moments on the tyre–road contact area. In the
third case, a piece of software has been embedded in an easy-to-use graphic user interface (GUI ) to
analyse vehicle cornering behaviour as predicted by the popular ‘one-track model’. In the first two
cases the focus lies on the construction, on the instrumentation and on the use of the experimental
set-up, whereas in the third case the focus is centred on the equations used to represent the model,
on the simplifications made, on the properties used, on the numerical integration and on the layout
of the designed GUI.
The three ‘experimental’ facilities mentioned in the The fact that an automobile is a moving machine com-
previous paragraphs are used in automotive technology plicates the set-up of experiments related to the vehicle
courses in either the University of Seville or the University itself or to any of its subsystems. Testing the braking
of Castilla–La Mancha. In the case of the University of system of a vehicle, for example, may require a dedicated
Seville (where both authors worked together until just a test track as well as sophisticated on-board equipment.
few years ago), the facilities are used as part of a set of On the other hand, if it were possible to keep the vehicle
interconnected experiments used to train the students in stationary, the experimental set-up would be consider-
understanding vehicle issues related to vehicle dynamics, ably simplified. Eliminating the forward velocity of the
power plant technology, tyre technology and suspension vehicle while simulating the moving road underneath is
and steering system integration. This laboratory work is done in many instances in automotive testing. In the case
part of an automotive technology course that has been of brake testing, however, the added complication of
taught since 1985. It is believed that the course provides simulating the vehicle longitudinal inertia needs to be
the European automotive industry with highly trained solved. In the present rig, this is done by transforming
engineers who are well suited to work in any of the the road into rotating drums whose added moment of
branches of this industrial sector. inertia with respect to their respective axis of rotation
(its respective axles) equals the mass of the vehicle times
the drum’s radius squared. This condition also implies
2 ABS WORKBENCH that the added kinetic energy of the rotating drums is
that of the vehicle.
2.1 Purpose of the experimental rig The experimental workbench has been constructed
The purpose of the experimental rig is to be able to show in collaboration with a local component manufacturer
how the braking system of a heavy vehicle works; to be whose main business lies on the field of semi-trailer
able to show the effects of excessive braking pressure pneumatic brakes. This led the authors to design a test
without an antilock brake system (ABS) in the con- rig suitable for typical three-axle configurations. How-
trol loop; to be able to measure vehicle speed, wheel ever, this decision made it desirable to scale down the
slip, pseudo-slip and pressure near the air actuator size of the wheels and drums since a huge device would
chambers, in order to be able to show their variations be uncomfortable to operate. An effort has been made
and fluctuations during the braking process; and mainly to scale down all relevant parameters in accordance with
to be able to show the effects of an ABS control. These dimensional analysis. Nevertheless, it is clear that most
purposes are achieved with the workbench depicted in of the pneumatic components must be used in their
Fig. 1, where a three-axle configuration is mounted on original size. Moreover, it was not easy to maintain
powered rotating drums that play the role of the road. simultaneous similitude in the case of vertical load and
The drums are brought up to ‘cruising’ speed by an vehicle mass. Nevertheless, since the purpose is to show
electric motor and are left to rotate freely until the the performance of the system, rather than to pre-
braking system is activated. A dedicated data acquisition dict specific vehicle behaviour, the lack of complete
system has been assembled to record data from the similitude is not considered to be a major drawback. The
moment the brakes are applied until the vehicle (the same reason may be argued in order to disregard the
drums in this case) stops. effect of load transfer during braking, the influence of
Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering D13802 © IMechE 2004
slip [defined in the usual manner as S=(v−vR)/V ] saturate. Percentage slip is also shown in Fig. 9. Figure 10
grows significantly (Fig. 9) the control system kicks in, shows how the control pressure is constant whereas the
reducing brake pressure. This makes the wheel speed pressure that reaches the air actuator is modulated by
recover, guaranteeing that the friction force does not the control system.
Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering D13802 © IMechE 2004
3 SLIDING TABLE FOR TYRE TESTING forces on a body that give rise to the deformations.
Nevertheless, it is possible to twist the reasoning some-
3.1 Experimental set-up and purpose what. It is possible to fix the deformation kinematics of
the body providing the means for generating whatever
Forces on solid bodies are necessarily related to defor- forces are required to cope with the motion. This is the
mations and it is not possible to have either one without case with the sliding table of Fig. 11. No forces can be
the other. The causality principle implies that it is the applied to a tyre without the tyre deforming, which is
D13802 © IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering
guides that permit the sliding motion of the table top. understanding and retention. Traditionally the student
This motion is powered by a motor underneath the table spends a lot of time on such things as deriving the
top (Fig. 13). The motor pinion is meshed to a rack equations of motion and then programming them using
fixed to the sliding table top. a traditional programming language. This approach
Figure 14 shows the wheel positioning devices. often turns out to be more of a programming problem
Figure 14a shows the device on the vertical post that with compiling, debugging, etc. This takes attention
allows for slip angle selection and Fig. 14b shows the away from the solution and understanding the real
device at the wheel’s axle that permits the camber angle problem, in this case the solution of the equations
to be fixed. The horizontal beam of the supporting arm of motions of the ‘bicycle model’. However, by using
can rotate with respect to the vertical post. This rotation a direct interactive visual approach to learning, it is
can be fixed at any of the predefined closely spaced possible to remove many of the conventional barriers
angles by means of the locking pin shown in Fig. 14a. that hinder effective teaching and learning of seemingly
Likewise, the wheel axle can rotate with respect to the abstract scientific and engineering concepts, by reducing
horizontal post, but this rotation can be fixed by means the barriers and obstacles between the student and the
of the locking pin shown in Fig. 14b. concept.
The model that will be used in the interactive
MATLAB interface is known in the literature as the
4 LINEAR ONE-TRACK MODEL bicycle or one-track model, as described in the intro-
duction. The one-track model assumes a stiff chassis
Experience has shown that active visualization-based with its centre of gravity (CG) lying in the plane of the
learning using interactive programs can greatly enhance road. The angle between the speed vector v and the longi-
tudinal axis of the vehicle is called the slip angle b of
the vehicle, which in general is not identical with the
steering angle d.
The suspension of the vehicle is ignored in this model,
thus neither the roll nor the pitching motion of the
vehicle is evaluated. Therefore the CG is assumed to be
located level with the road. Furthermore. the model is
only accurate for small and moderate lateral accelerations,
since the bicycle model is decreasingly applicable with
growing lateral force. Segel [1] says that it can be used
if the lateral acceleration is not greater than 0.4 g. In
the case of the linearized model it will be valid where
the bicycle model holds and the tyres are more or less
linear—except for the study motion on a road with a
low friction coefficient such as snow or ice on the road,
where the slip angle can also become large for small
cornering forces.
In order to reduce the error caused by neglecting the
pitch of the vehicle, the acceleration in the longitudinal
direction will be minimized in the simulation, i.e. the
longitudinal component of the acceleration ẍ=a =0.
x
From the longitudinal equilibrium it can be deduced
effortlessly that the pitching motion also will become
Fig. 13 Traction motor zero.
D13802 © IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering
(a) (b)
The forces exerted on the two front wheels are 4.2 Dynamic equilibrium
assumed to be indistinguishable; the same holds for the
In this paper the equations are expressed as scalar
rear wheels. This makes it possible to replace the front
equations. It is desirable to express these without intro-
and rear wheels with one wheel in the centre of the
ducing the heading angle so ‘vehicle fix coordinates’ are
vehicle subjected to the sum of the original forces. This
used; otherwise an extra integration would be needed in
wheel will have double the cornering stiffness of the
the solution (to keep track of the heading angle).
original wheel. The model will the simulate a vehicle with
The road is considered to be flat and so the motion
two unsprung wheels in one track (similar to a bicycle,
will be planar. The equilibrium of forces gives (see
consequently the name) with no pitch or roll.
Fig. 15)
There are two coordinate systems used to describe
A B
the vehicle: the global system (X, Y, Z) and the vehicle dV
fixed system (x, y, z) with the x axis pointing in the ma =m x −V V =F +F cos (d)−F sin (d)
x dt y xr xf yr
longitudinal direction of the vehicle and the y axis being
A B
positive to the driver’s right-hand side (according to the dV
ma =m y +V V =F +F sin (d)+F cos (d)
SAE definition [2]). y dt x yr xf yr
(3)
4.1 Solicitation input
and the equilibrium of moments gives
There are two different types of input to the model. The
user can choose either step input or sinusoidal input to dV
I =−F c+F sin (d)b+F cos (d)b (4)
the steer angle (d). The step input is defined as a sudden dt yr xf yf
change of the steer angle at t=0 s; i.e. the steer angle
changes from zero to a value delta given by the user
(or by the default of the interface). The definitions of 4.3 Different tyre models
the step and the sinusoidal inputs are given by
The tyre model plays an important role in the perform-
ance of the vehicle model. With the exception of aero-
G
0, t<0
d= (1) dynamic forces, which are only relevant at higher speeds,
d , t0 all of the interactions of the vehicle with the external
step
d=d sin (2p ft) (2) environment occur through the tyre. Accurate modelling
amp of the tyre is essential to a precise vehicle simulation.
where d is the amplitude, f is the frequency and t is A common approach to calculate the lateral force
amp
the time. The default is a step change and the sinusoidal generated by the tyre is to use either a linearization
steer can be activated by the user by pushing the radio [as in equation (5) below] or the Magic Formula Tire
button on the interface. Model [3], which gives more precise results for larger
Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering D13802 © IMechE 2004
slip angles. The formula is based on a function whose Fig. 16 and the mathematical definition is given later
behaviour approximates the shape of the curves obtained in equation (6).
from experimental measurements on tyres. Its parameters
are determined so as to fit the curve to a particular set
of experimental results. A problem in many empirical/ 4.3.1 Linear tyre model
numerical approaches is that it requires a large amount The formulation of a linear tyre model is defined below.
of test data which can be difficult and expensive to obtain The lateral force for the rear and front tyres can be
by testing and is often difficult, or even impossible, to expressed as
find by a literature search. However, due to the nature
of this study, a method will be used which has a simpler F =C a
yf af f
mathematical expression that mimics the most important,
F =C a
overall features of the Magic Formula with fewer para- yr ar r
meters. The method often referred to as the brush model (5)
[4], will be used in this paper. The advantage is that it
is still non-linear but does not require experiments where C and C are the cornering stiffness for the front
af ar
and/or analysis. A graphic presentation can be seen in and rear axles respectively.
D13802 © IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering
C A B D
bV+V
+C d-atan y l (2−l )
af V f f
x
4.4 Numerical model: linear model
The numerical model for the linear case will be derived
by inserting the equation for the linear tyre (5) in the
×cos (d)−V V
x H (16)
G A B
equations of equilibrium, (3) and (4). The equations will dV 1 cV−V
= −C atan y l (2−l )c
then become dt I ar V r r
x
A B C A B D
dV bV+V
m x −V V =F +F cos (d)−C a sin (d) +C d-atan y l (2−l )
dt y xr xf af f af V f f
x
H
(8)
×cos (d)b (17)
A B
dV
m y +V V =C a +F sin (d)+C a cos (d)
dt x ar r xf af f where equations (16) and (17) are the governing
equations of the vehicle dynamics with the tyre model
(9) included and the influence of the elasticity. The standard
simplification of small angles is not considered because
dV
I =−C a c+F sin (d)b+C a cos (d)b a closed solution is not necessary and the equations are
dt af r xf af f easy to solve numerically. Equations (13) to (15) are
(10) again needed to find out the global heading angle y and
the global coordinates X and Y.
It is also assumed that the angles are small and that the
longitudinal speed is constant. Inserting equation (7)
and simplifying yields 5 THE INTERFACE
A B
dV C +C C b−C c
m y + af ar V + mV + af ar V=C d The interface is divided into several fields with input to
dt V y x V af
x x the bicycle model, feedback and a result visualization
(11) field (see Fig. 17). The different groups are given as
follows:
A B
dV C b−C c C b2+C c2
I + af ar V + af ar V=C bd A. Vehicle parameter input field. This field has some
dt V y V af default values as an example for the user. These
x x
(12) values can all be changed by editing the values. The
parameters are the location of the centre of gravity,
The following three equations are needed to find out the suspended mass of the vehicle and the cornering
the global heading angle y and the global coordinates stiffnesses of the tyres.
Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering D13802 © IMechE 2004
B. Input related to the input solicitation are in this field, F. Plot area. In this area the results are visualized. In
i.e. the degree of the step input or the amplitude and the example calculated in Fig. 17 the user selects the
frequency of the sinusoidal solicitation, as well as checkbox in order to visualize the results for the
the forward speed and a field for the end-time of the linear and non-linear model.
simulation. G. Calculation button. This button runs the calculation
C. Field for choosing results to plot. Results can be used and automatically plots the lateral velocity and the
in a variety of ways to analyse vehicle manoeuvring jaw velocity.
motions, handling and stability. A large number of
vehicle input and response variables can be selected
for plotting using the time history and XY formats.
A set of two results will be selected and represented
6 SOME NUMERICAL EXAMPLES
as a plot. In order to plot, the button in field E has
to be pressed.
6.1 Over- or understeer
D. Feedback information field. Here additional infor-
mation about the results is presented and alerts on In the information field the student can see feedback on
the validity of the model are issued. The understeer the most recent simulation. For instance, in Fig. 18 the
coefficient is calculated and displayed; if this is results from three different calculations can be seen. Four
negative then the critical speed is also calculated. different parameters can be monitored in this field. First
The maximum lateral acceleration is calculated and is the understeer coefficient K (see Ia or IIIa in Fig. 18);
us
an alert is given if this acceleration is higher than if the value K is positive it means that the vehicle is
us
0.4g (in that case the results are not valid). For understeered and if the value is negative the vehicle
examples see the next section. is oversteered. If that is the case the vehicle is unstable
E. Plot button. This button plots the result of any result above a certain velocity v , which is automatically
crit
that has been chosen. calculated (see IIIa or IIIb in Fig. 18). The lateral
D13802 © IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering
acceleration (a ) is calculated in order to find out 6.2 Numerical example of different solicitations
y
whether the simulation is valid or not. For accelerations
higher than 0.4–0.5 the bicycle model will give inaccurate There are two different types of solicitation to the bicycle
results. Therefore the user has feedback on whether or model, step change of the steer angle and a sinusoidal
not it is higher than ay>0.4 (see Ib or IIa in Fig. 18). change. In Fig. 19 the results of these two solicitations
The user can also observe the absolute value of the maxi- were plotted. The vehicle modelled had the same para-
mum acceleration in the field a (see Ic or IIb in meters and the velocity was the same. The step steer angle
y,max
Fig. 18). and the amplitude of the sinusoidal where identical. It
Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering D13802 © IMechE 2004
D13802 © IMechE 2004 Proc. Instn Mech. Engrs Vol. 218 Part D: J. Automobile Engineering